Stator of motor having bus-bar wiring structure and method of wiring coil in parallel using the same

ABSTRACT

Disclosed is a method of wiring a coil in parallel around a stator having a plurality of teeth, which includes the steps of: winding the coil around a tooth starting from a top or a bottom of the stator; continuously winding the coil around an adjacent tooth when winding on the tooth is completed; cutting an end portion of the coil positioned at either the top or the bottom of the stator; wiring the cut end portion of the coil using a bus-bar; and wiring a neutral point to the other end of either the top or the bottom of the stator.

CROSS REFERENCE TO PRIOR APPLICATIONS

This application is a Divisional Application of U.S. patent applicationSer. No. 14/490,678 filed on Sep. 19, 2014, which claims priority toKorean Patent Application No. 10-2013-0141079 filed on Nov. 20, 2013,which are all hereby incorporated by reference in their entirety.

BACKGROUND

The present invention relates to a motor. More particularly, the presentinvention relates to a structure applying a bus-bar in order to wire acoil wound around a stator in parallel and a method of winding the coilusing the same.

Generally, a motor or a generator is used by wiring a plurality of coilswound around a stator. Particularly, most of AC motors or generatorswire the coils in parallel. In the case of such parallel wiring, sincean end of a wound coil should be connected to each tooth of the stator,the number of coils to be wired is considerably large, and thus wiringmethods more convenient and having good electrical characteristics whileavoiding electrical interference with each phase are proposed.

Particularly, a structure applying a bus-bar to avoid electricalinterference with other phases while connecting the same phase isfrequently employed to wire the coils. Korean Laid-opened Patent Nos.10-2008-0068437, 10-2010-46922, and 10-2010-0059548 disclose a method ofwiring of coils using a bus-bar. According to such a conventionalbus-bar structure, since an end of each coil should be connected to aconnection tab of a bus-bar while a plurality of coils is protrudedtoward the top of the stator core, it is difficult to do the work.

Specifically, in the case of Korean Patent No. 10-2008-0068437,electrical wiring is performed by inserting an end portion of a coilprotruding upward into a coil insertion hole formed in the bus-bar. Inthis case, since the end portions of some coils which are not insertedgenerate interference when the end portion of the coil is inserted intothe hole, it is very difficult to simultaneously insert a plurality ofcoil end portions into the holes, respectively. In addition, in the caseof Korean Patent Nos. 10-2010-46922 and 10-2010-0059548, the endportions of the coils should be respectively connected to connectiontabs of the bus-bar while being protruded toward the top, the work isvery difficult to do, and it is possible to connect a coil to a wrongconnection tab.

In order to solve these problems, Korean Patent Registration No.10-1146440 improves workability by bending and aligning two ends of acoil wound around a tooth toward an upper insulator and then positioningthe coil at a coil lead unit of a bus-bar housing corresponding to theposition of each coil.

However, since Korean Patent Registration No. 10-1146440 requires toomany working processes since each end should be cut and wired afterwinding a coil around each tooth and, in the case of 3-phase parallelwiring, bus-bars for connecting U, V and W phases to a neutral point areconcentrated on one bus-bar housing, there is a limit in improving thespeed of work.

Therefore, in order to solve the problems described above, inventors ofthe present invention propose a stator of a motor having a bus-barwiring structure, which applies a structure enabling parallel wiring byapplying a method of sequentially winding one coil around all teeth, anda method of wiring the coil in parallel.

SUMMARY

Therefore, the present invention has been made in view of the aboveproblems, and it is an object of the present invention to provide astator of a motor having a bus-bar wiring structure of a new type.

Another object of the present invention is to provide a stator of amotor having a bus-bar wiring structure with improved workability.

Still another object of the present invention is to provide a new methodof wiring a coil wound around a stator.

The above and other inherent objects of the present invention will beeasily accomplished by the present invention described below.

To accomplish the above objects, according to one aspect of the presentinvention, there is provided a stator of a motor having a bus-bar wiringstructure, the stator including: a stator core configured of a core basein which a plurality of teeth is formed; an upper insulator coupled to atop of the stator core to insulate the teeth; a lower insulator coupledto a bottom of the stator core; a coil wound around the teeth when theupper insulator and the lower insulator are coupled; and a lower bus-barhousing coupled to a top of the upper insulator and having a pluralityof bus-bar insertion units formed to insert a plurality of bus-bars.

In the present invention, the stator may further include: a neutralpoint bus-bar insertion unit formed at an outer periphery of the lowerinsulator; and a neutral point bus-bar inserted into the neutral pointbus-bar insertion unit.

In the present invention, a plurality of neutral point coil connectionunits may be formed in the neutral point bus-bar insertion unit, andsome of coils positioned at a lower portion of the teeth may be wired tothe neutral point coil connection units.

In the present invention, the stator may further include an upperbus-bar housing coupled to a top of the lower bus-bar housing.

In the present invention, a plurality of power terminal lead units maybe formed on an inner side surface of the upper bus-bar housing.

According to one aspect of the present invention, there is provided amethod of wiring a coil in parallel around a stator having a pluralityof teeth, the method including the steps of: winding the coil around atooth starting from a top or a bottom of the stator; continuouslywinding the coil around an adjacent tooth when winding on the tooth iscompleted; cutting an end portion of the coil positioned at either thetop or the bottom of the stator; wiring the cut end portion of the coilusing a bus-bar; and wiring a neutral point to the other end of eitherthe top or the bottom of the stator.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a stator of a motor having abus-bar wiring structure according to the present invention.

FIG. 2 is an exploded perspective view showing an exploded part of astator of a motor according to the present invention.

FIG. 3 is a perspective view showing a lower insulator and a neutralpoint bus-bar of a stator of a motor according to the present invention.

FIG. 4 is a perspective view showing a coil wound around a stator of amotor according to the present invention.

FIG. 5 is a bottom surface view showing a coil wound around a stator ofa motor according to the present invention.

FIG. 6 is a perspective view showing bus-bar wiring performed at astator of a motor according to the present invention.

FIG. 7 is an exploded perspective view showing an exploded bus-barhousing applied to a stator of a motor according to the presentinvention.

FIG. 8 shows a pattern diagram of a coil wound around a stator of amotor according to the present invention.

FIG. 9 shows a pattern diagram when a coil wound around a stator of amotor is wired to bus-bars according to the present invention.

DETAILED DESCRIPTION

The preferred embodiments of the invention will be hereafter describedin detail, with reference to the accompanying drawings.

FIG. 1 is a perspective view showing a stator 100 of a motor having abus-bar wiring structure according to the present invention.

As shown in FIG. 1, a stator 100 of a motor according to the presentinvention is configured of a stator core 10, an upper insulator 20, alower insulator 30, a coil 40 and a bus-bar housing 50.

The stator core 10 is generally manufactured in the form of an iron corestacking a plurality of thin iron plates. A detailed configuration ofthe stator core 10 will be described with reference to FIG. 2.

FIG. 2 is an exploded perspective view showing an exploded part of astator 100 of a motor according to the present invention.

Referring to FIG. 2, the stator core 10 of the present invention isconfigured of a core base 11 having a shape of a circular ring, aplurality of teeth 12 formed on the inner surface of the core base 11 ina radial shape toward the center, and teeth ears 13 respectively formedat an end of each tooth 12 and slightly extended toward both sides. Arotor (not shown) is positioned toward the inside of the teeth ear 13,i.e., at a position toward the center of the core base 11. That is,since the rotor positions and rotates at the inside of the stator core10, the stator 100 shown in FIG. 1 is applied to a motor of an innerrotor type. Accordingly, the teeth 12 have a shape formed toward thecenter of the core base 11, and the present invention is not necessarilylimited to such a shape, but the teeth 12 are formed toward theperiphery of the core base 11 so as to be applied to a motor of an outerrotor type in which the rotor rotates at the outside of the stator 100,by forming the teeth 12 to be positioned toward the periphery of thecore base 11.

Referring to FIGS. 1 and 2, the upper insulator 20 and the lowerinsulator 30 are coupled to the top and bottom of the stator core 10,respectively. The upper insulator 20 is configured of an outer diameterunit 21, a teeth insulation unit 22, an inner diameter unit 23 and abus-bar housing connection unit 24. Each of these parts is preferablymanufactured using one insulating resin molding.

The outer diameter unit 21 is a part which covers a portion or all ofthe top and a portion of the inner side surface of the core base 11. Theteeth insulation unit 22 is formed toward the inside of the outerdiameter unit 21 to wrap the teeth 12. The teeth insulation unit 22covers the top and side surfaces of the teeth 12 and a portion of theinner side surface of the core base 11. A coil 40 is wound around theteeth insulation unit 22, and the teeth insulation unit 22 performs aninsulation function between the inner side surfaces of the coil 40 andthe teeth 12 and between the coil 40 and the core base 11. The innerdiameter unit 23 covering the top of the teeth ear 13 is formed at anend of the teeth insulation unit 22. The inner diameter unit 23 isformed to be protruded toward the top by a predetermined height toprevent the coil from being protruded toward the inside when the coil 40is wound. A plurality of bus-bar housing connection units 24 is formedat the outer diameter unit 21. As shown in FIG. 2, the bus-bar housingconnection unit 24 may have a shape of a hole for inserting a projectionor may have a shape for applying a hook shaped or other well-knownconnection means.

The lower insulator 30 is coupled to the bottom of the stator core 10,and although the lower insulator 30 has a configuration similar to thatof the upper insulator 20, there is a difference. A detailedconfiguration related thereto will be described below with reference toFIG. 3.

The coil 40 is wound around each of the teeth 12 while the upperinsulator 20 and the lower insulator 30 are coupled to the stator core10. In the present invention, when a thread of the coil 40 completes tobe wounded around one of the teeth, it is not cut there and wound aroundanother tooth at an adjacent position, and winding of the coil iscompleted for all the teeth by sequentially repeating this process.After the winding process like this is completed first, a process forparallel wiring is performed. Therefore, the winding work can beperformed using a winding device having only one nozzle. Compared with aconventional parallel wiring, in which when winding a coil around atooth is completed, the coil is cut and both of the ends of the coil areprocessed, and in the case of a 3-phase series connection, three teethare simultaneously wound using three nozzles, the present invention maysimplify the winding device.

The stator 100 shown in FIG. 1 has a structure applied to a nine-slotmotor and is connected through a 3-phase parallel Y-connection. Ofcourse, the number of slots and phases is not necessarily limitedthereto. For the parallel connection, the stator 100 according to thepresent invention performs wiring of a neutral point at the lowerinsulator 30 side, and wiring each of three phases is performed at thebus-bar housing 50 coupled to the top of the upper insulator 20. To thisend, bus-bars for wiring each phase are installed inside the bus-barhousing 50, and details thereof will be described below.

FIG. 3 is a perspective view showing a lower insulator 30 and a neutralpoint bus-bar 64 of a stator 100 of a motor according to the presentinvention, from the bottom of the stator.

As shown in FIG. 3, the lower insulator 30 of the present invention isconfigured of an outer diameter unit 31, a teeth insulation unit 32 andan inner diameter unit 33. The lower insulator 30 is preferablymanufactured using an insulating resin molding, like the upper insulator20. The outer diameter unit 31 covers a portion or all of the bottom anda portion of the inner side surface of the stator core 10. The teethinsulation unit 32 covers the bottom and side surfaces of each tooth 12and a portion of the inner side surface of the core base 11. The teethinsulation unit 22 of the upper insulator 20 and the teeth insulationunit 32 of the lower insulator 30 are contact and combined with eachother so that all the inner side surface of the core base 11 and thetop, bottom and inner side surfaces of the teeth 12 may be insulated.The inner diameter unit 33 has a shape slightly protruded upwards at anend of the teeth insulation unit 32.

A neutral point bus-bar insertion unit 34 for inserting a neutral pointbus-bar 64 is formed in the outer diameter unit 31. The neutral pointbus-bar 64 is shaped in a circular ring having a plurality of neutralpoint coil connection units 64 a. FIG. 3 shows a case of forming fiveneutral point coil connection units 64 a. In the case of parallelwiring, when a coil is wound around a tooth, one end of the coil shouldbe connected to the neutral point, and the other end should be connectedto a coil of the same phase and an external power terminal. Since theneutral point bus-bar 64 should be connected to one of two ends of thecoil wound around each tooth for all the teeth, the five neutral pointcoil connection units 64 a are formed to wire the ends of the coilswound around nine teeth, i.e., nine coil ends. Since one neutral pointcoil connection unit 64 a may connect one ends of the coils of twoadjacent teeth, four coil connection units for connecting one ends oftwo coils and one coil connection unit for connecting one end of a coilare applied. Of course, although the number of the neutral point coilconnection units 64 a may be changed diversely, since the length of acoil should be adjusted to connect an end of the coil, in the case of anine-slot motor, it is preferable to apply five neutral point coilconnection units 64 a as shown in FIG. 3 and share one coil connectionunit 64 a by the coils of two adjacent teeth.

FIG. 4 is a perspective view showing a coil 40 wound around a stator 100of a motor according to the present invention, and FIG. 5 is a bottomsurface view thereof.

Referring to FIGS. 4 and 5, when the coil 40 is wound around the stator100 of the present invention, the coil is wound while the upperinsulator 20 and the lower insulator 30 are coupled to the stator core10. Winding of the coil 40 starts from point A of FIG. 4. That is, whenwinding on a tooth is completed from the upper insulator 20 side, thecoil proceeds toward the lower insulator 30, and winding on an adjacenttooth starts from the lower insulator 30 side. If winding on theadjacent tooth is completed, the coil 40 is positioned at the upperinsulator 20 side and proceeds to an adjacent tooth. A view of windingthat is sequentially completed on adjacent teeth is shown in FIG. 4. Thecoil protruded toward the top has a form connecting two adjacent teeth,and this connected portion is cut and discarded as a scarp 40 a, andthen the end of each coil is wired to a bus-bar corresponding to eachphase of the bus-bar housing 50.

Wiring of the neural point is accomplished by the neutral point bus-bar64 coupled to the lower insulator 30. Referring to FIG. 5, if winding ofthe coil 40 sequentially proceeds toward an adjacent tooth, the windingis completed at point B. Of course, the winding may start from point Band complete at point A of FIG. 4. The coils wound around two adjacentteeth are wired by the neutral point coil connection unit 64 a of theneutral point bus-bar 64, and the coil wound around the last one toothis wired to the neutral point coil connection unit 64 a positioned atpoint B. Therefore, one of two ends of each of the coils wound aroundthe nine teeth is electrically connected to one of two ends of anothercoil. For the electrical connection and physical coupling of the neutralpoint coil connection unit 64 a and the coil 40, it is preferable tobend the neutral point coil connection unit 64 a and then apply fusingwelding.

Wiring of the neutral point is accomplished by the neutral point bus-bar64 coupled to the lower insulator 30 as described above. Wiring of eachphase is accomplished by the bus-bar of the bus-bar housing 50 coupledto the upper insulator 20, and this will be described in detail withreference to FIGS. 6 and 7.

FIG. 6 is a perspective view showing bus-bar wiring performed at astator 100 of a motor according to the present invention, and FIG. 7 isan exploded perspective view showing an exploded bus-bar housing 50.

As shown in FIGS. 6 and 7, the bus-bar housing 50 has a structure ofcombining a lower bus-bar housing 51 and an upper bus-bar housing 52.

A first bus-bar insertion unit 51 a, a second bus-bar insertion unit 51b and a third bus-bar insertion unit 51 c for inserting a bus-bar forwiring three phases are formed inside the lower bus-bar housing 51.These three bus-bars are for wiring u, v and w phases, i.e., each ofthree phases, and various numbers of bus-bars other than the threebus-bars can be applied according to the number of phases.

A first bus-bar 61 is for wiring one of three phases, for example, the uphase, and a coil wound around three teeth corresponding to the u phaseamong the nine teeth is wired to the first bus-bar 61. Accordingly,three first coil connection units 61 b are formed in the first bus-bar61, and each of the first coil connection units 61 b is extended by afirst outer diameter extension unit 61 a formed toward the outerdiameter. When the first bus-bar 61 is inserted into the first bus-barinsertion unit 51 a, the first outer diameter extension unit 61 a isrested on a resting unit at a position corresponding to the first outerdiameter extension unit 61 a among a plurality of resting units 52formed in the lower bus-bar housing 51. An end of the coil 40 iselectrically connected to the first coil connection unit 61 b, andalthough a variety of methods such as soldering, compressing, weldingand the like can be applied as a connection method, the electrical andphysical connection is preferably accomplished by fusing welding. Afirst power connection unit 61 c is separately formed in the firstbus-bar 61, and the first bus-bar 61 is electrically connected to anexternal power through the first power connection unit 61 c.

A second bus-bar 62 is for wiring one of three phases, for example, thev phase, and a coil wound around three teeth corresponding to the vphase among the nine teeth is wired to the second bus-bar 62.Accordingly, three second coil connection units 62 b are formed in thesecond bus-bar 62, and each of the second coil connection units 62 b isextended by a second outer diameter extension unit 62 a formed towardthe outer diameter. When the second bus-bar 62 is inserted into thesecond bus-bar insertion unit 51 b, the second outer diameter extensionunit 62 a is positioned at a resting unit formed at a positioncorresponding to the second outer diameter extension unit 62 a among theplurality of resting units 52 formed in the lower bus-bar housing 51. Anend of the coil 40 is electrically connected to the second coilconnection unit 62 b, and although a variety of methods such assoldering, compressing, welding and the like can be applied as aconnection method, preferably, the electrical and physical connection isaccomplished by fusing welding. A second power connection unit 62 c isseparately formed in the second bus-bar 62, and the second bus-bar 62 iselectrically connected to an external power through the second powerconnection unit 62 c.

A third bus-bar 63 is for wiring one of three phases, for example, the wphase, and a coil wound around three teeth corresponding to the w phaseamong the nine teeth is wired to the third bus-bar 63. Accordingly,three third coil connection units 63 b are formed in the third bus-bar63, and each of the third coil connection units 63 b is extended by athird outer diameter extension unit 63 a formed toward the outerdiameter. When the third bus-bar 63 is inserted in the third bus-barinsertion unit 51 c, the third outer diameter extension unit 63 a isplaced at a resting unit formed at a position corresponding to the thirdouter diameter extension unit 63 a among the plurality of resting units52 formed in the lower bus-bar housing 51. An end of the coil 40 iselectrically connected to the third coil connection unit 63 b, andalthough a variety of methods such as soldering, compressing, weldingand the like can be applied as a connection method, preferably, theelectrical and physical connection is accomplished by fusing welding. Athird power connection unit 63 c is separately formed in the thirdbus-bar 63, and the third bus-bar 63 is electrically connected to anexternal power through the third power connection unit 63 c.

A plurality of housing fixing units 53 is formed on the outer sidesurface of the lower bus-bar housing 51 or toward the bottom. For thehousing fixing unit 53, a shape of a latching projection may be appliedas shown in FIG. 7, or a variety of shapes may be applied according tothe shape of the bus-bar housing connection unit 24 formed in the upperinsulator 20.

A plurality of upper housing fixing units 54 is formed on the outer sidesurface of the lower bus-bar housing 51 or toward the top. For the upperhousing fixing unit 54, a shape of a hook may be applied as shown inFIG. 7, or a variety of other coupling structures may be applied. Theupper housing fixing units 54 are inserted into coupling grooves 55 bformed in the upper bus-bar housing 55.

The upper bus-bar housing 55 is combined with the lower bus-bar housing51 and performs a function of protecting the bus-bars and the likecoupled inside the lower bus-bar housing 51 from outside. A plurality ofpower terminal lead units 55 a is formed on the inner side surface ofthe upper bus-bar housing 55, and the power terminal lead unit 55 aprovides a space for electrically connecting an external power to eachbus-bar.

FIG. 8 shows a parallel wiring pattern diagram of a coil 40 wound arounda stator 100 of a motor according to the present invention.

As shown in FIG. 8, in the case of a nine-slot motor, winding of thecoil 40 starts from point A placed at the upper portion of the stator100. When winding on a first tooth is completed first, the coil moves toa second tooth adjacent at the lower portion of the stator 100 and iswound around the second tooth starting from the lower portion. Whenwinding on the second tooth is completed, winding of the coil startsfrom the upper portion of a third tooth adjacent at the upper portion ofthe stator 100. If these steps are repeated and winding is completed upto the ninth tooth, the winding is completed at point B placed at thelower portion of the stator 100. Like this, after winding one coilaround the first to ninth teeth at a time without cutting the coil inthe middle, X portions of the coil connecting two adjacent teeth on thetop of the stator 100 are cut, and the scraps 40 a, which are cutportions, are removed. Then, the coils positioning at the lower portionof the stator 100 are wired to the neutral point coil connection units64 a, respectively. Of course, wiring of the neutral point coils may beperformed before the coils positioned at the top of the stator 100 arecut.

FIG. 9 shows a pattern diagram when a coil wound around a stator 100 ofa motor is wired to bus-bars 61, 62, 63 and 64 according to the presentinvention.

As shown in FIG. 8, when winding and cutting of the coil is completed,the neutral point on the bottom of the stator 100 is in a state beingwired as described above with reference to FIG. 8. Referring to FIG. 9to describe the steps performed thereafter, while winding of the coilhas already been completed, the first bus-bar 61 is wired to the coilsof the first, fourth and seventh teeth to connect the u phase. In thesame manner, the second bus-bar 62 is wired to the coils of the second,fifth and eighth teeth to connect the v phase, and the third bus-bar 63is wired to the coils of the third, sixth and ninth teeth to connect thew phase. The other end of each bus-bar is electrically connected to anexternal power.

In FIGS. 8 and 9, although each phase is wired using a bus-bar at thetop of the stator 100 and a neutral point is wired at the bottom of thestator 100, contrarily, the neutral point may be wired at the top of thestator 100 and each phase may be wired using the bus-bar at the bottomof the stator 100 according to the structure of a motor.

The present invention has an effect of providing a stator of a motorhaving a bus-bar wiring structure to improve workability through abus-bar wiring structure of a new type and providing a new method ofwiring a coil wound around a stator.

While the present invention has been described with reference to theparticular illustrative embodiments, it is not to be restricted by theembodiments but only by the appended claims. It is to be appreciatedthat those skilled in the art can change or modify the embodimentswithout departing from the scope and spirit of the present invention.

What is claimed is:
 1. A method of wiring a coil in parallel around astator having a plurality of teeth, the method comprising the steps of:winding the coil around a tooth starting from a top or a bottom of thestator; continuously winding the coil around an adjacent tooth whenwinding on the tooth is completed; cutting an end portion of the coilpositioned at either the top or the bottom of the stator; wiring the cutend portion of the coil using a bus-bar; and wiring a neutral point tothe other end of either the top or the bottom of the stator.